Control mechanism for wirebound box-making machines



Jan. 30, 1962 l.. vooRHEEs 3,018,482

CONTROL MECHANISM FOR WIREBOUND BOX-MAKING MACHINES Filed July 22, 1960 s sheets-sheet 1 Jan. 30, 1962 T. L. vooRHEEs CONTROL MECHANISM FOR WIREBOUND BOX-MAKING MACHINES Filed July 22, 1960 3 Sheets-Sheet 2 JNVENToR. Thomas L. Voorhees ATTORNEYS.

I Curl/ls, Marr/'s Safford Ulli Jan. 30,1962 T. L. vooRHEEs CONTROL MECHANISM FOR WIREBOUND BOX-MAKING MACHINES 5 Sheets-Sheet 3 Filed July 22, 1960 JNVENToR. Thomas L. Voorhees "if M i Z/ Cuff/Q, Morris 8 Safford A T Ton/VE Ys.

United States Patent() 3,018,432 CONTRL MECHANISM FOR WIREBGUND BOX-MAKING MACHlNES Thomas L. Voorhees, Morris Plains, NJ., assignor to Stapling Machines Co., Rockaway, NJ., a corporation of Delaware Filed July 22, 1960, Ser. No. 44,762 4 Claims. (Cl. 1-147) rIhis invention relates to wirebound box-making machines and more particularly to an improved mechanism for maintaining synchronization of the operation of the several mechanisms of the machine under a wide range. of operating conditions.

U.S. Patent No. 2,304,510, issued December 8, 1942, discloses a wirebound box making machine of the general type to which the present invention relates. In such machines, properly assembled cleats and side material or slats are conveyed by continuously moving conveyor bands beneath a transverse bank of stapling units which drive stap-les astride longitudinally extending binding wires, through the side material or slats, and into the cleats to form wirebound box blanks. The conveyor bands and the stapling units are driven from a common electric motor through separate clutches. When both of these clutches are engaged, the box parts are continuously moved beneath the stapling units by the conveyor bands at a uniform rate and the staple forming and driving elements of the stapling units are reciprocated at a predetermined frequency, so that staples are driven into the moving box 'parts at uniform intervals-the so-called basic staple spacing.

When the design of the particular type of box or crate blank being fabricated necessitates that the` adjacent staples in each longitudinal row of staples be spaced a distance greater than this basic staple spacing, the clutch through Which the stapling units are driven is temporarily disengaged, while the clutch through which the conveyor bands are driven remains engaged. Thus theI work will continue to move past the stapling units Without any staples being driven. When the stapling unit clutch is again reenizaged, staples will again be driven, and the space between the lirst staple so driven and the last staple driven prim' to disengagement of the clutch will be greater than the basic staple spacing by a distance proportional to the length of time that the stapling unit clutch was disengaged.

U.S. Patent No. 2,482,370, issued September 20, 1949,

discloses a box making machine having a remote pattern control chain for controlling the stapling unit clutch to position the staples along the box or crate blanks as desired. This pattern control chain is driven by and in synchronism with the conveyor bands through a clutch which is electrically controlled by a switch actuated by control elements on the conveyor bands. These control elements actuate the switch to energize the clutch and initiate movement of the pattern chain each time the leading end of a box or crate blank arrives in position to be operated on by the stapling units. The clutch is disengaged to stop the pattern chain by means of a separate switch actuated by a control element on the pattern chain each time the pattern chain completes one revolution. Other control elements spaced along the pattern chain actuate a pattern switch which controls the stapling unit clutch. The arrangement is such that alternate ones of these control ele-ments (known as knock-in pins) actu.- ate the pattern switch to cause engagement of the stapling unit clutch and the intervening elements (known as knockout pins) actuate the switch to cause disengagement of the clutch. These pins are so positioned on the pattern chain that the stapling unit clutch is engaged and ICC disengaged at such times that the staples are driven into the moving box blanks at the desired positions.

The stapling unit clutch is actuated by a cam on the stapling unit drive shaft units through a toggle assemb-ly. The arrangement is such that the cam will actuate the clutch only if the two links of the toggle are aligned with each other; if the toggle is bent at its knee it is removed from engagement with the cam. This arrangement not only derives the power for operating the clutch from the main motor through the stapling unit drive shaft, but it insures that the stapling units are always stopped at the top of their stroke, when they are out of engagement with the moving box parts. This primary toggle assembly is actuated by a solenoid and/ or a pneumatic cylinder.

In machines of the type disclosed in the aforementioned patents, the several stapling units are driven in synchronism by a common drive shaft. Strands of staple wire are fed to the respective stapling units by individual drive wheels which frictionally engage the wire, and during each stapling cycle the staple former and driver act to cut olf a length of wire from the strand, form it into a staple and drive it into the box-parts.

U.S. Patent No. 2,578,936 discloses a control mechanism for enabling the driving of staples in irregular patterns in which one or more of the stapling units do not drive staples during certain of the stapling cycles, by selectively controlling the feeding of wire to the respective stapling units.

The feeding of wire to the several units is controlled by a remote pattern chain which, like the remote pattern chain which controls the stapling unit clutch, is an endless chain which makes one-revolution during the formation of each box blank. The pattern chain which con- Atrols the stapling unit clutch is driven from the conveyor band drive shaft, while the pattern chain which controls the wire feed is driven from the stapling unit drive shaft.

When the machine is stopped and restarted during the making of a box blank, it is possible forthe two pattern chains to getout of synchronization. This is particularly true where the manual switch is thrown to the stop position just before the last staple of a group of staples is driventhat is, just before the knockout pin on the remote pattern chain has engaged the pattern control switch. The over-travel of the conveyor bands and the remote pattern chain may cause the knockout pin to engage the switch before the conveyor bands and remote pattern chain come to a stop, throwing the pattern control switch to the position for disengaging the stapling unit clutch. Therefore, when the manual switch is again thrown to the run position, the stapling units will not function to drive the last staple in the group.

Another possible difculty arises where the machine is stopped when the high point of the cam which actuates the stapling unit clutch is opposite the toggle, so that the toggle cannot straighten until the next revolution of the cam, during which interval an additional staple is driven.

vSince the wirefeed control chain is driven from the stapling unit drive shaft, its movement is dependentupon the number of stapling cycles, and Where more or less staples than are called for by the pattern are actually driven, the two pattern chains get out' of synchronization, and culls will be produced. This condition normally continues until itis noticed by the operator and the machine is again stopped and the pattern chains are manually returned to synchronization.

The present invention provides la practical mechanism for automatically re-synchronizing the operation of the pattern chains, if necessary, at the commencement of the making of each successive box blank, thereby avoiding the production of culls due to the aforementioned causes and also lavoiding the necessity of stopping the machine for manual re-setting of the pattern chains.

3 In the drawings: FIGURE l is a fragmentary side elevational view of a wirebound box-making machine embodying features of the present invention, showing the wirefeed mechanism and a portion of the remote wirefeed control chain.

' FIGURE 1A is a fragmentary side elevational view of a different portion of the machine of FIGURE 1, showing part of the remote stapling pattern control chain and associated mechanism.

FIGURE 2 is a staggered sectional view of the wirefeed control mechanism shown in FIGURE l, taken on vthe line 2 2 of that figure.

FIGURE 3 is a fragmentary sectional view of the wirefeed control mechanism shown in FIGURE 2, taken on line 3--3 of that figure.

FIGURE 4 is a fragmentary isometric view of a por- `tion of the remote pattern chain of the wirefeed control mechanism which appears at the near side of the set of chains in FIGURE 1 and at the bottom of FIGURE 2.

FIGURE 5 is a fragmentary top plan view of the remote staple pattern control mechanism, taken from the line 5 5 in FIGURE 1A.

FIGURE 6 is a fragmentary side elevational View of the clutch and brake actuating mechanism of the machine.

FIGURE 7 is a schematic diagram of the electrical circuit which controls the clutch `and brake of the stapling mechanism, showing its relation to the overall electrical circuit of the machine.

FIGURE 8 is a fragmentary isometric view of a box blank having longitudinally spaced, intermediate cleat members requiring an intermittent stapling pattern.

In FIGURE l, the broken line A represents `a portion of the main frame at the right-hand side of a wirebound box-making machine of the general type disclosed more fully in the aforementioned patents. Journalled in this frame is one end of the wirefeed shaft 2 which drives the elements which feed staple wire W to the stapling units partially Shown at S, and which also drives the remote pattern chains which selectively control the wire feeding elements.

The support member 4 of each of the wire feeding mechanisms has attached to it a U-shaped member 6 and mounted on these members is a solenoid valve 8 which is supported at the upper end of a short pipe 10 by which it is connected to an air cylinder 12 secured to the face of the member 6. The downwardly projecting piston 14 of the air cylinder 12 has fixed at its lower end a head member 16 having a groove 18 formed therein to receive loosely a generally horizontally extending lever 20. The lever 20 is fixed at its center to one end of a stud 22 lwhich is rotatably mounted in the member 6 and which eccentrically and rotatablysupports on its opposite end a tension roller 24. The lever 20 is urged in a clockwise direction, as viewed in FIGURE 1, by means of a tension spring 28 whose lower end is hooked about a stud 30 projecting from the left-hand end of the lever 20 rand whose upper end is hooked through the lower end of a tension adjusting screw 32 threaded through a block 34 secured to the face of support member 4.

The spring 28 urges the lever 20 and stud 22 in ya clockwise direction, as viewed in FIGURE l, moving the tension roller 24 upwardly to press the staple wire W into frictional engagement with the knurled feed roller 26 which is rotated in a clockwise direction by the shaft 2, thus causing the staple Wire W to b e fed to the stapling unit S. Energization of the solenoid valve 8 causes compressed air to be supplied to the cylinder 12, driving its piston 14 downwardly and rotating the lever 20 and stud 22 in a counter-clockwise direction, lowering the tension roller 24 out of engagement with the staple wire W and stopping the feeding of wire to the stapling unit S.

The solenoid valve 8 is controlled to vary the pattern of staples driven by the respective stapling units by means of the wirefeed control mechanism shown at the right in FIGURE l,v and in FIGUREZ. This mechanism i s driven by a chain 36 trained about a sprocket 38 keyed to the wirefeed shaft 2 adjacent the inner face of the right-hand main frame A and yabout a sprocket 40 keyed to a short shaft 42 (FIGURE 2) journalled in a boss 44 integrally secured to the inner face of a vertical member 46 forming part of an open framework supported by the side frame of the machine. Removably secured to thc near end of the short shaft 42 as viewed in FIGURE 1 (the lower end as viewed in FIGURE 2) is an extension shaft 48 which has keyed thereon a plurality of sprockets 50 about which are respectively trained the several wirefeed pattern control chains 52. There is one of the pattern chains 52 for each of the several stapling units which are under wirefeed control. Adjustably positioned on the chains 52 are blocks 86 for controlling actuation of the respective wirefeed control switches B secured to vertical plates 56 attached to a T-shaped bracket 54 projecting from one side of the vertical framing member 46. The plungers of the switches B are actuated by levers 64 pivotally mounted on an elongated screw 62 projecting through the several vertical plates 56, these levers 64 being positioned for respective engagement by the blocks 86 on the pattern control chains 52.

The chain S2 at the near side of FIGURE l (the bottom of FIGURE 2) carries, in addition to the regular blocks 86, an extension block 94 which projects laterally from the outer side of the chain in position to engage the extension arm 68 projecting downwardly from a lever 66 pivotally mounted on the elongated screw 62. The portion of the extension block 94 adjacent the chain 52 is cut down as indicated at 96 so that the block will not engage and actuate the lever 64, but only the extension arm 68 and lever 66.

The upper end of the lever 66 is provided with laterally extending ears 76 and 78. Adjustably threaded through ear 78 is a screw 80. Screw 80 is adjusted so that it actuates the plunger 108 of stop switch 84 simultaneously with the actuation by ear 76 of the plunger 106 of another stop switch 82, the two stop switches 82 and 84 being fastened at opposite faces of a vertical plate 60 projecting upwardly from a bar 58 secured at the outer face of the outside plate 56.

The levers 64 and 66 are normally urged toward a vertical position by compression springs 70 and 72 which are respectively interposed between them and the bar 58.

A screw 74 threaded through lever 66 engages the adjacent edge of vertical plate 60 and functions as a stop to limit counterclockwise movement of lever 66 under the influence of the spring 72. As the pattern chains 52 are driven, the blocks 86 engage the respective levers 64, rocking them in a clockwise direction, as viewed in FIG- URE l, against the resistance of the springs 70, removing the set screws 88 from engagement with the plungers 90 of the respective switches B and opening their contacts, breaking the circuit to the respective solenoid valves 8. This actuates the valves 8 to remove the supply of compressed air from the cylinders 12 and allow the springs 28 to move the tension rollers 24 upwardly, and press the staple wires W into frictional engagement with the feed rollers 26 causing staple Wire to be fed to the respective stapling units S so that the stapling units will drive staples during the ensuing stapling cycle.

On each pattern chain y52 there is a block 86 for each stapling cycle in which the box design requires a staple to be driven by the stapling unit associated therewith, and each block 86 holds its levez` 64 depressed a suicient length of time for the feeding of the wire required for a single staple. When there is no block in the position corresponding to a given stapling cycle, the springs 70 move the levers 64 to their vertical position, causing the screws to depress the plungers 90 of the switches B, closing their contacts and energizing the solenoid valves 8. This actuates the valves to supply compressed air to the cylinders 12, lowering the tension wheels 24 out of engagement with the binding wireV W and stopping the feeding of the staple wire W to the stapling units S. The number and location of the blocks 86 on the respective wirefeed pattern chains 52 thus determines the number and relative positions of the staples driven by the respective stapling units S during the several stapling cycles which occur during the making of each box blank.

The wirefeed pattern chains 52 are designed to make one revolution during the passage of each box blank beneath the stapling units, Upon the completion of each revolution of the chains 52, the extension block 94 engages the extension arm 68 at the lower end of the lever 66, rocking the lever 66 in a clockwise direction, as viewed in FIGURE l, against the resistance of the spring 72, and simultaneously removing the ear 76 and screw 80 from engagement with the plungers 106 and 108 of the stop switches 82 and 84, respectively. As will be described more fully hereinafter in connection with the circuit diagram of FIGURE 7, this results in disengaging the clutch through which the stapling units and the wirefeed shaft 2 are driven, thereby stopping the movement of the wirefeed pattern chains 52.

Where a box blank of the type shown in FIGURE 8 is being made, which requires a staple to be driven at an intermediate point such as F adjacent the leading end E of the box blank, a dual purpose index block 98 shown in FIGURE 4 is used. This index block 98 is of sufficient length and height to engage and actuate both the lever 64 (FIGURE 1) and the extension member 68 of the lever 66.

FIGURES 1A and 5 show a remote staple pattern chain of the type disclosed more fully in the aforementioned Patent No. 2,864,086. This remote pattern chain 102 is driven in synchronism with the conveyor bands of the machine under control of a remote pattern clutch C and brake D (FIGURE 7). As disclosed more fully in said Patent No. 2,864,086, the clutch C and brake D are controlled by means of a start switch 124 (FIG. 7) which is actuated by an element projecting from one of the conveyor bands of the box-making machine just prior to the arrival of the leading end of a set of box parts beneath the transverse row of stapling units. The actuation of this start switch 124 releases the brake D and energizes the clutch C to cause the remote pattern chain 102 (FIG- URES 1A and 5) to be driven by and at the same linear speed as the conveyor bands. The length of the remote pattern chain 102 is approximately the same as the length of one of the box blanks and, like the pattern chains 52 (FIGURE 2), it accordingly makes one revolution during the formation of each box blank. Upon completion of each revolution of the chain 102, a stop element 116 (FIGURE 5) thereon engages a ilexible finger 118, actuating the stop switch 114 (FIGURES 1A and 7) which, as described more fully hereinafter, results in disengaging the clutch C and engaging the brake D to stop the chain 102.

As may be seen in FIGURES 1A and 5, mounted on top of the stop switch 114 and arranged to be actuated by the finger 118 simultaneously with the stop switch 114 is another stop switch 110 which, as is described hereinafter, is interconnected with the dual stop switches 82 and 84 (FIGURES l and 2) for control of the clutch through which the stapling units S, the wirefeed shaft 2 and the remote wirefeed control chains 52 are driven.

Adjustably positioned on the remote stapling pattern chain 2 are a series of alternate knock-in blocks 100 and knockout blocks 136 which, as disclosed more fully in the aforementioned Patent No. 2,482,370, index a sprocket which drives a cam which alternately opens and closes a pattern switch 104 (FIGURE 5 which, as also described hereinafter, controls the stapling unit clutch.

Now, with particular reference to the circuit diagram of FIGURE 7, we shall describe the sequence of operations of the mechanism during a box-making cycle. All of the circuit shown in FIGURE 7 need not be described because, with the exception of the portion of the circuit at the bottom of the figure, it is similar to the circuit which is shown and fully described in the aforementioned Patent No. 2,864,046.

When the motor M (FIGURE 7) is energized and the main control switch O is closed, the clutch through which the conveyor bands are driven is energized to cause the conveyor bands to be continuously driven.

At the commencement of the box-making. cycle, the member 116 (FIGURE 5) on the remote staple pattern chain 102 will be in engagement with the finger 118, depressing the plunger 120 of the stop switch 110 to throw its movable contact to the position opposite to that shown in FIGURE 7. Also, the extension block 94 (FIGURES 1 and 2) on the remote wirefeed pattern chain 52 will be in engagement with the extension arm 68 on the lever 66, causing the ear 76 and screw 80 (FIGURE 2) to release the plungers 106 and 108 of the dual stop switches 82 and 84, actuating these switches and throwing their movable contacts to positions opposite to those shown in FIGURE 7. Thus, the circuit to the windings of each of the three relays X, Y and Z is broken and all three of these relays are disengaged.

As the leading edge of a set of box pants on the moving conveyor bands approaches the transverse row of stapling units, the switch actuating element on one of the conveyor bands actuates the start switch 124, releasing the brake D and engaging the clutch C, causing the remote staple pattern chain 102 to be driven.

As soon as the movement of the remote staple pattern chain 102 has commenced, the member 116 (FIGURE 5) on the chain moves out of engagement with the finger 118, releasing the plunger 120 of the stop switch 110 and throwing its movable contact to the position shown in FIGURE 7. However, despite the fact that the remote wirefeed pattern chain 52 (FIGURES 1A and 5) will not yet have started its movement and the movable contacts of the stop switches 82 and 84 will still be held in positions opposite to those shown in FIGURE 7, the stop relay Y will not be energized due to the fact that the contacts Z1 of the reset relay Z are still open.

When the first knock-in pin 100 on the staple pattern chain 102 actuates the pattern switch 104, its contacts are closed, energizing the solenoid 122 through the normally closed contacts X2 and Y1 of the relays X and Y.

As may be seen in FIGURE 6, and as described more fully in the aforementioned Patent No. 2,864,086, energization of the solenoid 122 lifts its plunger, moving the link 134 from the position shown in full lines to the' position shown in broken lines, breaking the toggle 132 and removing the roller 128 thereon from engagement with the cam 130 on the stapling unit drive shaft, causing the stapling unit drive shaft brake to be released and the clutch to be engaged, causing the stapling units to be driven in regular cyclical operation to drive staples in the moving box parts at a uniform spacing.

As the wirefeed pattern control chain 52 starts its movement, the extension block 94 will be moved from engagement with the extension arm 68 of the lever 66, actuating the stop switches 82 and 84 and throwing their movable contacts to the position shown in FIGURE 7. rlhis will energize the reset relay Z, closing its contacts Z1 and Z2. The contacts Z2 serve as holding contacts which maintain the circuit to the winding of the relay Z so that it remains energized even after actuation of the stop switch 84 to the position opposite from that shown, so long as the stop switch remains in the position shown. The closure of its contacts Z1 readies the circuit for energization of the relay Y if the stop switch 84 is actuated before actuation of the stop switch 110, as described hereinafter.

Where the pattern of staples in the type of box being fabricated requires at one or more points along its length, a longitudinal spacing between consecutive staples in the box blank which is greater than the normal spacing, a knockout pin 136 (FIGURE 5) is employed to index the sprocket and open the pattern switch 104. This de-enera gizes the solenoid 122, straightening the toggle 132 (FIG- URE 6) and moving the roller 12S back into such position that upon the next revolution of the cam shaft, the high point of the cam 130 drives the roller and the associated linkage upwardly, disengaging the clutch and applying the brake to stop the stapling unit drive shaft, as well as the wirefeed mechanism and the wirefeed pattern chains. Meanwhile the conveyor bands continue to run and the length of time the stapling unit clutch is disengaged determines the spacing between adjacent staples in the pattern. Thus, the location of the knock-in pins 100 and knockout pins 136 (FIGURE 5) determines the positions of the staples along the length of the box blank.

After the set of box parts has passed beneath the row of stapling units and the stapling of the box blank has been completed, both the wirefeed pattern chains 52 and the staple pattern chain 102 (FIGURE 5) will each normally have completed a full revolution. The extension block 94 (FIGURES l and 2) on the remote wirefeed pattern chain will engage the extension arm 68 of the lever 66, actuating the stop switches 82 and 84. Also, the member 116 on the remote staple pat-tern chain 102 will engage the linger 11S, depressing the plungers of the stop switches 110 and 114.

As may be seen at the right in FIGURE 7, the actuation of the stop switch 114 disengages the clutch C and energizes the brake D to stop the movement of the rcmote staple pattern chain 102.

The actuation of the sop switches 82, 84 and 110 as described will throw their movable contacts to positions opposite to those shown in FIGURE 7, thus de-energizing the windings of all three of the relays X, Y and Z. This will open the contacts X1 and close the contacts X2 of relay X, and close the contacts Y1 of relay Y. This places the stapling clutch solenoid 122 under control of the stapling pattern switch 104 which, upon completion of the stapling operation upon the box blank will have been opened by the last knockout pin 136 (FIGURE 5) on the remote staple pattern chain 102. Thus, the solenoid 122 will be de-energized, allowing the toggle 132 (FIGURE 6) to straighten, placing the roller 128 in position to be engaged by the cam 130. When the high point of the cam next passes beneath the roller 128 the clutch which controls the stapling unit drive shaft will be disengaged and the brake will be applied to stop the operation of the stapling units. Simultaneously, the wirefeed shaft 2 (FIGURE 1) and the remote wirefeed pattern chains 52 will stop. The equipment is now in condition for the next box-making cycle.

As previously mentioned, where more or less than the desired number of staples are driven into any box blank, the remote wirefeed pattern chains 52 (FIGURES 1 and 2) and the remote staple patern chain 102 (FIGURES 1A and 5) ge-t out of synchronization. However, the operation of the two chains is automatically re-synchronized at the completion of the formation of each box blank and prior to commencement of the next box-making cycle, in

the manner now to be described.

For example, where one or more extra staples have been driven in the box blank, the remote wirefeed pattern chains 52 will lead the remote staple pattern chain 102. In that event, the stop switches 82 and 84 will be actuated prior to actuation of the stop switch 110. As may be seen by reference to FIGURE 7, the actuation of the stop switches 82 and 84 will throw their movable contacts to positions opposite to those in which they are shown. This will result in energizing the relay Y through the circuit which includes stop switch 110, stop switch 84, and the normally open contacts Z1 of the relay Z which, as mentioned above, will have been energized upon the first stapling cycle during the formation of the box blank.

The energization of the relay Y opens its normally closed contacts Y1, breaking the circuit to the solenoid 122 and immediately initiating the disengagement o-f the stapling unit clutch to stop the stapling units, the wirefeed mechanism and the remote wirefeed pattern chains 52 (FIGURE 1). However, the remote staple pattern chain 102 (FIGURES 1A and 5) will continue to run until the member 116 actuates the stop switch 110, throwing its movable contact to the position opposite to that shown in FIGURE 7. This will break the circuit to the winding of the relay Y, cle-energizing the relay and allowing its contacts Y1 to close, returning the electrical circuit to its initial condition. Thus both the remote wirefeed pattern chains 52 and the remote staple pattern chain 102 will have completed a full revolution and have been stopped in the synchronized position preparatory for the next cycle of operation.

If, on the other hand, less staples than required by the design of the particular type of box being fabricated in the machine have been driven, the remote staple pattern chain 102 will lead the remote wirefeed pattern chains 52. Thus, the stop switch will be `'actuated before actuation of the stop switches 82 and 84.

As may be seen in FIGURE 7, the actuation of the switch 110 will throw its movable contact to the position opposite to that shown, `while the contacts of the switches 82 and 84 remain in the positions shown. This will energize the lwinding of the relay X, closing its normally open contacts X1 and opening its normally closed contacts X2. This will shunt the pattern switch 104 and keep the stapling clutch control solenoid 122 energized despite the position of the pattern switch 104. Thus, the stapling unit clutch will remain engagedv and the stapling units will continue to go through the motions of driving staples in the inten/al between adjacent sets of box parts. The remote wirefeed pattern chains 52 (FIGURES 1 and 2) will also continue their movement to the point where the extension block 94 (FIGURES 1 and 2) actuates the stop switches 82 yand 84. This will throw their movable contacts to positions opposite to those shown in FIGURE 7, de-energizing the relay X, opening its contacts X1 and closing its contacts X2, and returning control of the clutch solenoid 122 to the pattern switch 104.

Since the last knockout block 136 (FIGURE 5) on the remote stapling pattern chain 102 will have actuated the pattern switch 104 to open its contacts, the circuit to the solenoid 122 will have been broken, and the stapling unit clutch will be disengaged to stop the stapling units, the wirefeed mechanism, and the remote wirefeed pattern chains 52. Thus, the remote wirefeed pattern chains 52 and the remote stapling pattern chain 102 will each have completed a full revolution and have been stopped in a synchronized position, preparatory for the next box-making cycle.

From the foregoing description, it will be appreciated that the present invention provides a control mechanism which automatically re-synchronizes the remote wirefeed pattern chain and the remote stapling pattern chain at the completion of each box cycle, if the two chains have gotten out of synchronization during the formation of a box blank due to manual stoppage of the machine or to any other cause, thus insuring that no more than one cull can be produced, and rendering it unnecessary to shut down the machine for manually re-synchronizing the pattern chains. However, it should be emphasized that the partlcular embodiment of the invention which is described herein and shown in the accompanying drawings is intended as merely illustrative of the principles of the invention Iand not as restrictive of the scope thereof, which is limited only by the appended claims.

I claim:

1. In a wirebound box-making machine of the type hav ing conveyor bands for moving assembled box parts past a transverse row of stapling units, drive means for driving said conveyor bands and said stapling units including an electrically controlled stapling clutch for controlling the driving of said stapling units, wirefeed mechanism driven through said stapling clutch for feeding wire to said stapling units, and electrically controlled wirefeed control means for selectively controlling the feeding ofwire by said wirefeed mechanism to the respective stapling units, the combination therewith of improved staple pattern control, means comprising an endless, movable stapling pattern carrier and means for driving the same in synchronism with said conveyor bands, adjustably positioned stapling control switch actuating members carried by said stapling pattern carrier, stapling control switch means actuated fby said stapling control switch actuating members and connected for control of said stapling clutch, first stop switch means having an actuating element positioned adjacent said stapling pattern carrier, a stop switch actuating member mounted on said stapling pattern carrier at such position as to actuate said rst stop switch means upon each revolution of said stapling control carrier, an endless, movable wirefeed pattern carrier and means for driving the same through said stapling unit clutch, adjustably positioned wirefeed control switch actuating members carried by said wirefeed pattern carrier, wirefeed control switch means actu-ated by said wirefeed control switch actuating members and connected for control of said wirefeed control means, second stop switch means having a control element positioned adjacent said wirefeed pattern carrier, a stop switch actuating element mounted on said wirefeed pattern carrier at such position as to actuate said second stop switch means upon each revolution of said wirefeed pattern carrier, said first and second stop switch means being so interconnected with said stapling control switch means for control of said stapling clutch that actuation of said second stop switch means before actuation of said iirstY stop switch means deenergizes said stapling clutch whereas actuation of said rst stop switch means before actuation of said second stop switch means results in maintaining said clutch energized despite actuation of said stapling control switch means and until actuation of said second stop switch means.

2. -In a wirebound box-making machine of the type having conveyor bands for moving assembled box parts past a transverse row of stapling units, drive means for driving said conveyor bands and said stapling units including an electrically controlled stapling clutch for controlling the driving of said stapling units, wirefeed mechanism driven through said stapling clutch for feeding wire to said stapling units, and electrically controlled wirefeed control means for selectively controlling the feeding of wire by said wirefeed mechanism to the respective stapling units, the combination therewith of improved staple pattern control means comprising an endless, movable stapling pattern carrier and means including an electrically controlled stapling pattern carrier clutch for driving the same in synchronism with said conveyor bands, adjustably positioned stapling control switch actuating members carried by said stapling pattern carrier, stapling control switch means actuated by said stapling control switch actuating members and connected for control of said stapling clutch, start switch means mounted adjacent the path of one of said conveyor bands, a switch actuating member mounted on said one conveyor band for actuation of said start switch means prior to arrival of each set of box blank parts beneath said row of stapling units, first and second stop switch means having actuating elements positioned adjacent said stapling pattern carrier, said start switch means and said first stop switch means being interconnected for control of said stapling pattern carrier clutch whereby actuation of said start switch means engages said stapling pattern carrier clutch to cause movement of said stapling pattern carrier and actuation of said first stop switch means disengages said stapling pattern carrier clutch to stop said stapling pattern carrier, a stop switch actuating member mounted on said stapling pattern carrier at such position as to actuate said first and second stop switch means upon each revolution of said stapling control carrier, an endless, movable wirefeed pattern carrier and means for driving the same through said stapling unit clutch, adjustably positioned wirefeed control switch actuating members carried by said wirefeed pattern carrier, wirefeed control switch means actuated by said wirefeed control switch actuating members and connected for control of said wirefeed control means, third stop switch means having a control element positioned adjacent said wirefeed pattern carrier, a stop switch actuating element mounted on said wirefeed pattern carrier at such position as to actuate said third stop switch means upon each revolution of said wirefeed pattern carrier, said second and third stop switch means being so interconnected with said stapling control switch means for control of said stapling clutch that actuation of said third stop switch means before actuation of said second stop switch means de-energizes said stapling clutch whereas actuation of said second stop switch means before actuation of said third stop switch means results in maintaining said clutch energized despite actuation of said stapling control switch means and until actuation of said third stop switch means.

3. In a wirebound box-making machine of the type having conveyor bands for moving assembled box parts past a transverse row of stapling units, drive means for driving said conveyor bands and said stapling units including an electrically controlled stapling clutch for controlling the driving of said stapling units, wirefeed mechanism driven through said stapling clutch for feeding wire to said stapling units, and electrically controlled wirefeed control means for selectively controlling the feeding of wire by said wirefeed mechanism to the respective stapling units, the combination therewith of improved staple pattern control means comprising an endless, movable stapling pattern carrier and means for driving the same in synchronism with said conveyor bands, adjustably positioned stapling control switch actuating members carried by said stapling pattern carrier, a stapling control switch arranged to be actuated by said stapling control switch actuating members, a rst stop switch having an actuating element positioned adjacent said stapling pattern carrier, a stop switch actuating member mounted on said stapling pattern carrier at such position as to actuate said first stop switch upon each revolution of said stapling control carrier, an endless, -movable wirefeed pattern carrier and means for driving the same through said stapling unit clutch, adjustably positioned wirefeed control switch actuating members carried by said wirefeed pattern carrier, wirefeed control switch means actuated by said wirefeed control switch actuating members and connected for control of said wirefeed control means, a second stop switch having a control element positioned adjacent said wirefeed pattern carrier, a stop switch actuating element mounted on said wirefeed pattern carrier at such position as to actuate said second stop switch upon each revolution of said wirefeed pattern carrier, rst and second stop relays respectively controlled by said first and second stop switches, said first stop relay having contacts connected in parallel with the contacts of said stapling control switch and said second stop relay having contacts connected in series with such parallel-connected contacts and with the electrical control element of said stapling clutch across a source of electrical current, whereby actuation of said second stop switch before actuation of said first stop switch opens the contacts of said second stop relay and immediately breaks the circuit to said electrical control element and de-energizes said stapling clutch whereas actuation of said first stop switch before actuation of said second stop switch closes the contacts of said rst stop relay, shunting said stapling control switch and maintaining the circuit to said electrical control element to keep ysaid stapling clutch engaged until said second stop switch is actuated to open the contacts of said second stop relay.

4. In a wirebound box-making machine of the type lhaving conveyor bands for moving assembled box parts past a transverse row of stapling units, drive means for driving said conveyor bands and said stapling units including an electrically controlled stapling clutch for controlling the driving of said stapling units, wirefeed mechanism driven through said stapling clutch for feeding wire to said stapling units, and electrically controlled wirefeed control means for selectively controlling the feeding of wire by said wirefeed mechanism to the respective stapling units, the combination therewith of improved staple pattern control means comprising an endless, movable stapling pattern carrier and means including an electrically controlled stapling pattern carrier clutch for driving the same in synchronism with said conveyor bands,'

adjustably positioned stapling control switch actuating members carried by said stapling pattern carrier, a stapling control switch arranged to be actuated by said stapling control switch actuating members, a start switch having an actuating element positioned adjacent one of said conveyor bands, a switch actuating member mounted on said one conveyor band for actuation of said start switch prior to arrival of each set of box blank parts beneath said row of stapling units, rst and second stop switches having actuating elements positioned adjacent said stapling pattern carrier, said start switch and said lirst stop switch being interconnected for control of said stapling pattern carrier clutch whereby actuation of said start switch engages said stapling pattern carrier clutch to cause movement of said stapling pattern carrier and actuation of said iirst stop switch disengages said stapling pattern carrier clutch to stop said stapling pattern carrier, a stop switch actuating member mounted on said stapling pattern carrier at such position as to actuate said iirst and second stop switches upon each revolution of said stapling control carrier, an endless, movable Wirefeed pattern carrier and means for driving the same through said stapling unit clutch, adjustably positioned wirefeed control switch actuating members carried by said wirefeed pattern carrier, wirefeed control switch means actuated by said wirefeed control switch actuating members and connected for control of said wirefeed control means, a third stop switch having a control element positioned adjacent said wirefeed pattern carrier, a stop switch actuating element mounted on said wirefeed pattern carrier at such position as to actuate said third stop switch upon each revolution of said wirefeed pattern carrier, a reset relay having a winding connected in series with the contacts of said second and third stop switches across a source of electrical current whereby said reset relay is energized only after the actuating elements of both said second and third stop switches have been released by movement of both said pattern carriers from their stop positions, a iirst stop relay having a winding connected in series with normally open contacts of said first stop switch and with normally closed contacts of said third stop switch across a source of electrical current, and having normally open contacts connected in parallel with the contacts of said stapling control switch and a second stop relay having a winding connected in series with normally closed contacts of said second stop switch, normally open contacts of said third stop switch and normally open contacts of said reset relay across a source of electrical current, and having normally closed contacts connected in series with said parallel-connected contacts of said iirst stop relay and said stapling control switch and the control element of said stapling clutch across a source of electrical current, whereby actuation of said second stop switch before actuation of said third stop switch energizes said first stop relay closing its normally open contacts to bypass said stapling control switch and maintain the engagement of said stapling clutch until actuation of said third stop switch, and actuation of said third stop switch before actuation of said second stop switch energizes said second stop relay to open its normally closed contacts and initiate disengagement of said stapling clutch before actuation of said second stop switch.

No references cited. 

